11 37 010 Removing and installing/replacing intermediate levers (N20)
Special tools required:
Necessary preliminary tasks:
- Remove CYLINDER HEAD COVER
- Remove INJECTOR SHAFTS .
- Remove stop screws for eccentric shaft
Slowly adjust eccentric shaft (1) to minimum lift via servomotor using 4-mm hexagon socket wrench (2) and open-end spanner (3).
Release bolt (1) on the oil spray nozzle.
Tightening torque: 11 37 4AZ .
Unclip oil spray nozzle (2) from the bracket on the actuator drive (3) in direction of arrow.
Position special tool 11 7 110 on return spring (1) (see arrows).
Place special tool 11 7 110 flat on cylinder head.
Turn knurled screw (1) in direction of arrow until both clamping levers secure return spring in gate.
Return spring is correctly preloaded when both clamping levers are parallel to guide block.
Left and right return springs (1) must be positioned in lateral guide of special tool 11 7 110 .
Preload return spring with lever (1) on special tool 11 7 110 in direction of arrow.
Lock special tool 11 7 110 with catch on lever (1).
Release screw (1).
Lever (1) is preloaded.
Secure lever (1).
Press back latching hook (2).
Return spring tension can now be released.
Release knurled screw (1) on special tool 11 7 110 in direction of arrow.
Release special tool 11 7 110 in direction of arrow from return spring (1).
Press return spring (1) apart.
Remove return spring (1) upward.
Place all components in a clean and orderly condition in special tool 11 4 481 .
In the case of an engine which has already been in use, all components must be reinstalled in the same positions.
- Eccentric shaft with bearing
- Bearing caps of eccentric shaft (set out in order)
- Intake camshaft
- Bearing caps of intake camshaft (set out in order)
- Intake valves with valve springs
- Valve heads and valve keys
- Rocker arm with hydraulic valve clearance compensating element (set out in order).
- Return springs.
- Gates (set out in order)
- Intermediate levers (set out in order)
Release screws (1) on gate (2).
Tightening torque 11 37 1AZ .
Place all gates (2) in neat order in special tool 11 4 481 .
Installation note:
Mixing up the gates (2) will cause the engine to suffer idle-speed fluctuations.
Installation note:
All contact surfaces (1) of gates must be clean and free from oil and grease. If necessary, clean contact surfaces (1).
Lift out intermediate levers (1).
Place all intermediate levers (1) in neat order in special tool 11 4 481 .
Installation note:
Mixing up the intermediate levers (1) will cause the engine to suffer idle-speed fluctuations.
Installation note:
All contact surfaces must be clean and free of oil and grease. If necessary, clean contact surfaces.
All intermediate levers are classified.
All intermediate levers must be reinstalled in the same positions in an engine which has already been in use.
Intermediate levers are classified from 1 to 5.
Risk of damage!
Install intermediate levers (1).
Fit gate (2) cleanly into recess.
Tighten screws (1) hand-tight.
Check that intermediate levers are in correct installation position.
Release screws (1) by a 1/4 turn.
Secure special tool 11 4 450 on screw connection of eccentric shaft and set adjusting screw on special tool 11 4 450 , if necessary.
Turn eccentric lever on special tool 11 4 450 in direction of arrow.
Gate is now preloaded.
Fasten screws (1) of gates.
Tightening torque 11 37 1AZ .
Installation note:
At cylinder no. 3, the gate can be pre-installed with one screw (internal) only.
Oil spray nozzle is fitted only after return spring has been installed.
Graphic N55.
Press return spring (1) apart.
Install return spring (1).
Graphic N55.
Install return spring (2) on gate.
Installation note:
Insert return spring (2) in intermediate lever (1) (see arrow).
Check that rocker arm (3) is in correct installation position.
Position special tool 11 7 110 on return spring.
Clamp throttle return spring with knurled screw (1) in direction of arrow.
Return spring (1) is positioned correctly when latching hooks surround return spring (1).
Check return spring on intermediate lever to ensure correct installation position.
Press special tool 11 7 110 to stop in direction of arrow.
Tighten bolt (1).
Tightening torque 11 37 2AZ .
Retract oil spray nozzle (2) on actuator drive (3).
Engage bolt (1) and release back to 90°.
For exact positioning of the oil spray nozzle (2) audibly clip it in at the top.
Tightening torque 11 37 4AZ .
Assemble engine.